Polaris 600 IQ Racer Page 84 Owner'S Manual Download

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MAINTENANCE

Lights

Do not touch a halogen bulb with bare fingers. Oil from skin leaves a
residue, causing a hot spot that will shorten the life of the lamp. If fin-
gers do touch the bulb, clean it with an alcohol-moistened towel.

Headlight Bulb Removal

1. Remove the plenum covering

from the headlight assembly.

2. Pinch the ends of the spring (1)

together and lift until it
releases from the spring
retainer.

3. Lift spring carefully around

wire harness (2) and flip to
outside of housing.

4. With the wire harness attached to the bulb (3), withdraw bulb from

housing.

5. Grasp bulb by metal base and carefully separate bulb from harness.

Summary of Contents for 600 IQ Racer

Page 1: ...PMS 419 Snowmobile Owner s Manual for Maintenance and Safety 600 IQ Racer...

Page 2: ...ns in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to th...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922855 Rev 01 Printed in USA 9922855 PMS...

Page 5: ...sign and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations i...

Page 6: ...result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted...

Page 7: ...of your snowmobile s controls and features The Perfect Fit 29 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 40 This sectio...

Page 8: ...4...

Page 9: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary t...

Page 10: ...at snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE stan dards Our muffler systems are designed to reduce noise levels and must not be altered...

Page 11: ...the spaces pro vided Vehicle Model Number ___________________________________________________ Tunnel VIN ____________________________________________________________ right side of tunnel Engine Serial...

Page 12: ...rsonal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided...

Page 13: ...in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as di...

Page 14: ...n off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or cloth...

Page 15: ...will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterpro...

Page 16: ...where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tio...

Page 17: ...speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your...

Page 18: ...a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first veri...

Page 19: ...ow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow co...

Page 20: ...terfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an...

Page 21: ...to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may res...

Page 22: ...ance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you...

Page 23: ...is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold W...

Page 24: ...nd lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to a...

Page 25: ...ificate For their pro tection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumpi...

Page 26: ...3 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min...

Page 27: ...ING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard removed Never run engine with drive belt removed Never service clutches you...

Page 28: ...ed helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approve...

Page 29: ...25 FEATURES Safety Decals and Locations Track Warning No Passenger Warning Operation Warning...

Page 30: ...witch Tether Switch 3 Master Cylinder 4 Engine Stop Switch 5 Throttle Control 6 Recoil Starter Handle 7 Hold Down Straps 8 Fuel Filler Cap 9 Choke Control 10 Hand Thumbwarmer Switch 11 Brake Lever 12...

Page 31: ...GON mode for normal trail riding Unnecessary extended or excessive use of DRAGON mode can result in severe engine damage which is excluded from POLARIS warranty coverage DRAGON mode usually heats up t...

Page 32: ...aged at the starting line depress and hold the DRAGON button on the left handlebar 1 3 Slowly advance the throttle to the wide open position while keeping the button depressed 4 Release the button whe...

Page 33: ...and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle s...

Page 34: ...one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are hold ing the spring between the r...

Page 35: ...y Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a POLARIS dealer Shock Damping Walker Evans Sh...

Page 36: ...tyle With a little experimentation each rider can find a preferred setup These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide...

Page 37: ...on The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style Knob Adjustments Turn the knob toward the...

Page 38: ...here are two types of rear suspen sion coupling Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amoun...

Page 39: ...ng the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located o...

Page 40: ...ation move the stop to the rearward upper position The stop may also be rotated to a lower position for even more weight transfer if desired Low Position This setting will increase weight transfer Med...

Page 41: ...the bolts Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmo bile Use of una...

Page 42: ...clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel T...

Page 43: ...oper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s...

Page 44: ...Page Drive Belt Condition 83 Steering System 44 Recoil Rope 45 Coolant Level 72 Parking Brake Lock Brake Lever Brake System 42 43 76 Auxiliary Shut Off Switch Engine Stop Switch 46 Tether Switch Strap...

Page 45: ...oper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever...

Page 46: ...ke lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 77 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could res...

Page 47: ...light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the p...

Page 48: ...properly lubricated n Track WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Alw...

Page 49: ...ays ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile n Seat Latches If your snowmobile is equipped with a removable seat en...

Page 50: ...Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting n Tether Switch Remove the tether from the switch to make sure the engin...

Page 51: ...eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an en...

Page 52: ...Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fit ting machined...

Page 53: ...r flow rates All POLARIS oils are compatible with each other See page 100 for the part numbers of POLARIS products Fuel Recommendations Always use premium non oxygenated 92 octane fuel in this snowmo...

Page 54: ...r the part numbers of POLARIS products TIP When using oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives should not be used Drive Belt Break In The break in per...

Page 55: ...oggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF CHOKE position NOTICE Operating the vehicle immediately after cold starting could cause engine damag...

Page 56: ...fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat and result in brake failure n Engine Stop...

Page 57: ...to securely support the rear of the snowmobile at the rear bumper The track should be about 4I 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throt...

Page 58: ...ICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed Always maintain a visible level of oil...

Page 59: ...e performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Page 60: ...e The main jet installed in production is not correct for all altitudes and or temperatures See page 70 for more information NOTICE A main jet that s too small will cause a lean operating condition an...

Page 61: ...the tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact betwee...

Page 62: ...e with a minimum octane level of 91 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specificat...

Page 63: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty perio...

Page 64: ...00 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 82 I I I Drive Belt Condition 83 I I I I Clutches 82 C C C Belt Tension I I I I Clutch Sheaves 82 I...

Page 65: ...I I Brake System 42 76 I Brake Fluid 77 R FUEL MANAGEMENT Pilot Air Screws I I I Carburetor synchronize 70 I I I Idle RPM I I I Throttle Lever 41 I I I I I Throttle Cable 64 L L L Choke Cable 64 L L...

Page 66: ...I Drive Shaft Bearing 96 L L L I Jackshaft Bearings 96 L L L I Skags Wear Bars 93 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Post U Joint 63 L L L L L Steering Arm s L L L L I Upper Lower S...

Page 67: ...n Lubricate the suspension pivot shafts with POLARIS Premium All Sea son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 59 and before seasonal storage When operat...

Page 68: ...turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke i...

Page 69: ...oil level between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil POLARIS recommends the use of POLARIS Synthetic Chaincase Lube See page 100 f...

Page 70: ...conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Spark Plug Condition Spark plug condition is indicative of engine operation The spark plug...

Page 71: ...y adjustments Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General caus...

Page 72: ...re operating the snowmobile Variable Exhaust System VES Maintenance of the VES is limited to a periodic inspection and cleaning of system components Bring the machine to an authorized POLARIS dealer t...

Page 73: ...1600 km or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compoun...

Page 74: ...engine damage Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or...

Page 75: ...may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the gasoline warnings found on page 47 1 Turn the fuel valve off 2 Position a container or shop to...

Page 76: ...ute with water Never exceed a 60 antifreeze 40 water mixture See page 100 for POLARIS products NOTICE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the...

Page 77: ...g when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh m...

Page 78: ...Cycle the RPM from idle to enough RPM 4000 to get coolant to flow but not enough to engage the clutch This allows air to bleed from the rear crossover tube TIP There must be enough coolant flow to pu...

Page 79: ...r the exhaust system to cool Never perform this procedure with the engine running Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotat...

Page 80: ...functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes t...

Page 81: ...nt and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function View the brake fluid level through the sight glass on the top of the mas ter cylinde...

Page 82: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16I 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of...

Page 83: ...e center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be ai...

Page 84: ...oistened towel Headlight Bulb Removal 1 Remove the plenum covering from the headlight assembly 2 Pinch the ends of the spring 1 together and lift until it releases from the spring retainer 3 Lift spri...

Page 85: ...pring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Verify headlight aim Taillight Brakelight Replacement 1 Remove the screws sec...

Page 86: ...an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches ar...

Page 87: ...ature Reinstall it before starting the snowmobile n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and...

Page 88: ...to a complete stop 2 Apply the brake or lock the parking brake if equipped 3 Open the hood and remove the left side panel Remove the clutch guard retaining pin and open the clutch guard 4 Rotate the d...

Page 89: ...ification numbers so that you can read them If required separate the sheaves as out lined in the belt removal procedures 3 Rotate the L wrench counterclockwise to tighten the sheaves while working the...

Page 90: ...rts Never perform track measurement or adjustments with the engine run ning Track Inspection 1 Using a hoist safely lift and support the rear of the snow mobile off the ground WARNING Broken track rod...

Page 91: ...e and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other su...

Page 92: ...gine off 2 Lift the rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of...

Page 93: ...vide equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the machine is new 10 Start the machine and slowly rotate the t...

Page 94: ...Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track r...

Page 95: ...91 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary...

Page 96: ...our POLARIS dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt...

Page 97: ...to half their orig inal diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Some models are equipped with...

Page 98: ...ekly basis or before any long trip n Check suspension mounting bolts for tightness n Check rear idler wheel bolts for tightness See page 89 n Check rear idler adjusting bolt locknuts for tightness n C...

Page 99: ...g surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with...

Page 100: ...Repair Manual See your dealer Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during stor...

Page 101: ...torage 2 Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward 3 Remove the spark plug s 4 Rotate the engine slowly watching the p...

Page 102: ...h dielectric grease and re connect Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust...

Page 103: ...Turn the fuel valve clock wise to OFF to shut off the fuel supply Turn the valve counter clockwise to ON to turn the fuel supply on The fuel valve is located under the hood 2 Be sure the fuel cap is s...

Page 104: ...Cycle Engine Oil ltr 2877888 VES Gold Plus Synthetic 2 Cycle Engine Oil 4 ltr Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Gre...

Page 105: ...belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or loose...

Page 106: ...ssive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 92 octane fuel Engine doesn t turn Seized engine SEE YOUR DEALER Se...

Page 107: ...xture is too lean A main jet that is too small will cause seizure resulting in loss of power This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks p...

Page 108: ...ct shock Change to lighter valving if FOX shock Check track tension see page 88 Too much weight transfer when climb ing Adjust torsion spring preload see page 33 Adjust limiter straps Too little weigh...

Page 109: ...ease IFS preload if equipped see page 30 Install single skag see your dealer Rotate RRSS to high position see page 36 Steering is heavy Make sure spindles and all steering components turn freely Check...

Page 110: ...high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather an...

Page 111: ...contained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the followi...

Page 112: ...owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the mode...

Page 113: ...accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained or used for purpos...

Page 114: ...t the appropriate personnel at POLARIS if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the...

Page 115: ...dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warrant...

Page 116: ...s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authoriz...

Page 117: ...tices regarding your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased all warrant...

Page 118: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 119: ...xcludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty als...

Page 120: ...r each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED...

Page 121: ...117 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...118 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 123: ...oolant 72 Coolant Level 72 Cooling System 72 74 Cooling System Bleeding 73 74 Cooling System Flushing 73 D Disabled Operators 12 DRAGON Ignition System 27 28 DRAGON Mode Facts 27 Drive Belt Adjustment...

Page 124: ...P Parking Brake Lever Lock 43 Passenger Warnings 23 Preload IFS Shock Spring 30 Pre Ride Checklist 40 Pre Ride Suspension Inspection 94 Pressure Cap Warning 23 R Rail Slide Wear 93 Rear Rear Scissor S...

Page 125: ...orsion Spring Tension 33 Towing 57 Track 44 Track Alignment 90 Track Care for Storage 98 Track Inspection 86 Track Lubrication 87 Track Maintenance 86 90 Track Safety 10 Track Tension 32 88 89 Track W...

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Polaris 600 IQ Racer, Owner'S Manual

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